Ill (cid:9)
`0111011110111illps11211I1E111)111111111111101111111111
`US 20040178544A1
`
`US 20040178544A1
`
`(19) United States
`(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2004/0178544 Al
`(12) Patent Application Publication (io) Pub. No.: US 2004/0178544 Al
`Sep. 16, 2004
`Jackson et al. (cid:9)
`(43) Pub. Date: (cid:9)
`Jackson et al.
`(43) Pub. Date:
`Sep. 16, 2004
`
`(54) POLYMER TRANSFER APPARATUS,
`(54) POLYMER TRANSFER APPARATUS,
`METHODS, AND COMPOSITE WEBS
`METHODS, AND COMPOSITE WEBS
`
`(76)
`Inventors: Byron M. Jackson, Forest Lake, MN
`(76) Inventors: Byron M. Jackson, Forest Lake, MN
`(US); Randall L. Alberg, Maplewood,
`(US); Randall L. Alberg, Maplewood,
`MN (US); Dennis L. Becker, Vadnais
`MN (US); Dennis L. Becker, Vadnais
`Heights, MN (US); Roger D. Pavlis,
`Heights, MN (US); Roger D. Pavlis,
`Hudson, WI (US); Leigh E. Wood,
`Hudson, WI (US); Leigh E. Wood,
`Woodbury, MN (US)
`Woodbury, MN (US)
`
`Correspondence Address:
`Correspondence Address:
`3M INNOVATIVE PROPERTIES COMPANY
`3M INNOVATIVE PROPERTIES COMPANY
`PO BOX 33427
`PO BOX 33427
`ST. PAUL, MN 55133-3427 (US)
`ST. PAUL, MN 55133-3427 (US)
`
`(21) Appl. No.: (cid:9)
`(21) Appl. No.:
`
`10/387,699
`10/387,699
`
`(22) Filed: (cid:9)
`(22) Filed:
`
`Mar. 13, 2003
`Mar. 13, 2003
`
`Publication Classification
`Publication Classification
`
`(51)
`(51)
`
`Int. C1.7 (cid:9)
`Int. CI.7 (cid:9)
`
`(52) U.S. Cl. (cid:9)
`(52) U.S. CI(cid:9)
`
` B32B 3/26; B32B 3/06; B32B 27/00;
`B32B 3/26; B32B 3/06; B32B 27/00;
`B29C 41/00
`B29C 41/00
` 264/556; 428/306.6, 428/319.3
`264/556; 428/306.6; 428/319.3
`
`(57) (cid:9)
`(57)
`
`ABSTRACT
`ABSTRACT
`
`Composite webs having one or more polymeric structures
`Composite webs having one or more polymeric structures
`located on a substrate, methods of manufacturing the com-
`located on a substrate, methods of manufacturing the com
`posite webs, and systems for manufacturing the composite
`posite webs, and systems for manufacturing the composite
`webs are disclosed. The polymeric structures are formed
`webs are disclosed. The polymeric structures are formed
`using thermoplastic compositions deposited into one or
`using thermoplastic compositions deposited into one or
`more depressions on a forming tool. The forming tool is
`more depressions on a forming tool. The forming tool
`is
`maintained at a temperature that is below the melt process-
`maintained at a temperature that is below the melt process
`ing temperature of the thermoplastic composition.
`ing temperature of the thermoplastic composition.
`
`Petitioner - Owens Corning
`
`Ex. 1008, p. 1 of 32
`
`Petitioner - Owens Corning
`Ex. 1008, p. 1 of 32
`
`

`
`Patent Application Publication Sep. 16, 2004 Sheet 1 of 11 (cid:9)
`Patent Application Publication Sep. 16, 2004 Sheet 1 of 11
`
`US 2004/0178544 Al
`US 2004/0178544 A1
`
`Fig. I
`
`FIG. Z_
`fig. z.
`
`.....+.•••••i
`
`IN (cid:9)
`
`t IN (cid:9)
`
`lig
`
`iv° lit
`/
`]
`
`r//0 / / I. A2
`F/6.3
`FIG. 3
`
`/ 10
`
`Petitioner - Owens Corning
`
`Ex. 1008, p. 2 of 32
`
`Petitioner - Owens Corning
`Ex. 1008, p. 2 of 32
`
`

`
`Patent Application Publication Sep. 16, 2004 Sheet 2 of 11 (cid:9)
`Patent Application Publication Sep. 16, 2004 Sheet 2 of 11
`
`US 2004/0178544 Al
`US 2004/0178544 A1
`
`?o
`
`i
`
`HQ- 1
`
`39
`
`3a
`
`SIG.
`HQ- s-
`
`Petitioner - Owens Corning
`Ex. 1008, p. 3 of 32
`
`Petitioner - Owens Corning
`Ex. 1008, p. 3 of 32
`
`

`
`Patent Application Publication Sep. 16, 2004 Sheet 3 of 11
`Patent Application Publication Sep. 16, 2004 Sheet 3 of 11 (cid:9)
`
`US 2004/01 78544 A1
`US 2004/0178544 Al
`
`F/4 .
`
`(o
`
`Iwo (cid:9)
`
`I32 i3S- (cid:9)
`I3Z ,3.5
`
`13(0 (cid:9)
`
`it/5-- (cid:9)
`/ys-
`13C
`
`1341
`
`fig . i-
`
`Z35-
`
`25 <o
`
`-FIQ . ^
`
`Petitioner - Owens Corning
`Ex. 1008, p. 4 of 32
`
`Petitioner - Owens Corning
`Ex. 1008, p. 4 of 32
`
`

`
`Patent Application Publication Sep. 16, 2004 Sheet 4 of 11 (cid:9)
`Patent Application Publication Sep. 16, 2004 Sheet 4 of 11
`2-3Z_
`2.3Z_
`
`US 2004/0178544 Al
`US 2004/0178544 A1
`
`R6 • 1
`
`2.3q
`Z3V
`
`Z30
`Z3o
`
`330
`330
`
`I
`
`Q
`
`i
`
`TZ
`
`)
`
`^ e O o o^o Q;
`
`3s-0
`SIG. /0
`Fit?. 1°
`
`jz.
`IZ
`
`333
`
`33f
`
`^32.
`
`330
`
`Fig.
`m. n
`
`Petitioner - Owens Corning
`
`Ex. 1008, p. 5 of 32
`
`Petitioner - Owens Corning
`Ex. 1008, p. 5 of 32
`
`

`
`Patent Application Publication Sep. 16, 2004 Sheet 5 of 11 (cid:9)
`Patent Application Publication Sep. 16, 2004 Sheet 5 of 11
`
`US 2004/0178544 Al
`US 2004/0178544 A1
`
`31G
`
`(cid:9) 31
`
`3S2..
`35*2-
`
`31/
`alfrofeMAXWAW:07
`TSZZmr^
`310
`3o1
`t-3/Z-
`3/z._
`309 (cid:9)
`
`116.N. 1/4%N.IL
`
`331- 33(49
`
`HG13-
`
`-33(-1
`
`FL&
`F/b. I&
`
`3 so
`
`Hlo
`
`V//
`W IN
`'
`{/xWjx/x/v{'X>
`fICONICOPAWKIPAIMINWITIKOP:0:0:0470:0
`^ HZ-
`
`411rArdir.
`
`FIG. /y
`
`Petitioner - Owens Corning
`
`Ex. 1008, p. 6 of 32
`
`Petitioner - Owens Corning
`Ex. 1008, p. 6 of 32
`
`

`
`Patent Application Publication Sep. 16, 2004 Sheet 6 of 11 (cid:9)
`
`.U,.2(W4 8heet6»tU
`
`PatentAP^ttonPnWiCati0n ^
`
`J
`
`Fi G
`Fits - 15
`I S
`
`..m.......0...
`
`...MM,
`
`US 2004/0178544 Al
`
`pS2004/0478544A4
`
`:|(c- l(o
`
`ar OwensComing
`'100C8,P.7of32
`
`Petitioner - Owens Corning
`Ex. 1008, p. 7 of 32
`
`

`
`Patent Application Publication Sep. 16, 2004 Sheet 7 of 11 (cid:9)
`Patent Application Publication Sep. 16, 2004 Sheet 7 of 11
`
`US 2004/0178544 Al
`US 2004/0178544 A1
`
`-/V3
`
`SIG.
`m. /*
`
`Petitioner - Owens Corning
`
`Ex. 1008, p. 8 of 32
`
`Petitioner - Owens Corning
`Ex. 1008, p. 8 of 32
`
`

`
`Patent Application Publication Sep. 16, 2004 Sheet 8 of 11
`Patent Application Publication Sep. 16, 2004 Sheet 8 of 11 (cid:9)
`
`US 2004/0178544 A1
`US 2004/0178544 Al
`
`^
`
`A ^
`
`B
`
`slob
`Sid*
`
`C
`c
`
`,-5"14 0 c.
`-s-Hoc
`
`(X
`
`J
`
`O 0 0 CD CD
`> CD
`CD (
`o o
`O 0 0 0 CD V
`V(,V '
`)
`<(cid:9)
`)
`CD (
`o o
`b
`.
`0 0c=>
`O 0 (cid:9)
`<—)
`1
`)
`(
`>
`(
`o o
`a -y
`ci
`o o •=3 cD o A (cid:9)
`>
`<—> CD <(cid:9)
`o o
`o o 0 CD 0
`<—> C >
`>
`<(cid:9)
`o o
`O 0 0 0 0 0 0 4
`Vv> v
`x_7
`>
`(
`<—>
`>
`<(cid:9)
`o o
`V
`J
`)
`<(cid:9)
`o o CD (
`0 0 CD CD I=D
`tl I>
`o iv
`V
`>
`<(cid:9)
`o ? CD
`V
`Cn
`I
`534A (cid:9)
`
`S"3Y<l
`5-3/e.
`
`Cr CD
`SZ q 13 (cid:9)
`fig.
`TO. ft
`
`3a
`¦S3a
`
`"C
`
`430
`
`Ft zo
`F/G. Zo
`
`Petitioner - Owens Corning
`Ex. 1008, p. 9 of 32
`
`Petitioner - Owens Corning
`Ex. 1008, p. 9 of 32
`
`

`
`•
`c
`IS 20(14 Sheet 9 ofU
`Patent Application Publication Sep. 16, 2004 Sheet u
`Patent Application Publication Sep. 16, 2004 Sheet 9 of 11 (cid:9)
`
`US2004/0178544A1
`US 2004/0178544 Al
`
`(2 I
`
`Fife- 2-'
`
`fef?
`
`6110 Os- Gimp cols— ,c(114'
`6/s: fob
`6ii/
`¦777k(cid:9)
`/pyx
`
`^
`
`Colo
`6/0
`
`6/5"
`
`hlfe ^2-
`
`Petitioner - Owens Corning
`Ex. 1008, p. 10 of 32
`
`Petitioner - Owens Corning
`Ex. 1008, p. 10 of 32
`
`

`
`Patent Application Publication Sep. 16, 2004 Sheet 10 of 11
`Patent Application Publication Sep. 16, 2004 Sheet 10 of 11 (cid:9)
`7go
`75o
`
`US 2004/0178544 Al
`US 2004/0178544A1
`
`X
`
`( (cid:9)
`
`c
`
`(
`.••••••
`
`•••••••...•
`
`13o
`
`73 V
`
`is?.
`
`-15Z.
`nsz-
`
`Iv-L
`
`FIG- 73
`Pig- ^3
`
`n3
`
`(cid:9)
`
`<$(£>0
`
`rtl
`
`Fi(s- M
`
`Petitioner - Owens Corning
`Ex. 1008, p. 11 of 32
`
`7 -73,
`
`T~
`
`73(
`
`Petitioner - Owens Corning
`Ex. 1008, p. 11 of 32
`
`

`
`Patent Application Publication Sep. 16, 2004 Sheet 11 of 11 (cid:9)
`Patent Application Publication Sep. 16, 2004 Sheet 11 of 11
`
`US 2004/0178544 Al
`US 2004/0178544 A1
`
`*;--P
`er 4dX
`
`F16. zs4
`FIG
`
`eizqL
`
`q gib
`llOb
`
`F/6. 25^
`F-16. 25/3
`
`%
`
`efioc,
`^Y/O
`
`Zs-c,
`F76. Z?"d-
`
`4124
`qiU
`vid
`ellOci (cid:9)
`immsz*10*
`
`F76. z5:6
`Fi6. zzjb
`
`25cl
`
`Petitioner - Owens Corning
`
`Ex. 1008, p. 12 of 32
`
`Petitioner - Owens Corning
`Ex. 1008, p. 12 of 32
`
`(cid:9)
`

`
`US 2004/0178544 Al (cid:9)
`US 2004/0178544 A1
`
`Sep. 16, 2004
`Sep. 16, 2004
`
`1
`
`POLYMER TRANSFER APPARATUS, METHODS,
`POLYMER TRANSFER APPARATUS, METHODS,
`AND COMPOSITE WEBS
`AND COMPOSITE WEBS
`
`FIELD OF THE INVENTION
`FIELD OF THE INVENTION
`[0001] The present invention relates to composite webs
`[0001]
`The present invention relates to composite webs
`that include one or more polymeric structures on a substrate,
`that include one or more polymeric structures on a substrate,
`as well as methods and systems for manufacturing the
`as well as methods and systems for manufacturing the
`composite webs.
`composite webs.
`
`BACKGROUND
`BACKGROUND
`[0002] The manufacture of articles formed of webs that
`[0002]
`The manufacture of articles formed of webs that
`require some reinforcement to withstand forces experienced
`require some reinforcement to withstand forces experienced
`during use are known. In many cases, reinforcement is
`during use are known.
`In many cases, reinforcement
`is
`simply provided over the entire substrate or web. Such
`simply provided over the entire substrate or web. Such
`approaches can, however, add cost and weight to the web, as
`approaches can, however, add cost and weight to the web, as
`well as stiffness over the entire surface of the web—even in
`well as stiffness over the entire surface of the web—even in
`those areas that do not require reinforcement. Furthermore,
`those areas that do not require reinforcement. Furthermore,
`reinforcing layers that are coextensive with the web may
`reinforcing layers that are coextensive with the web may
`also reduce its breathability.
`also reduce its breathability.
`
`[0003] To address some of these issues, smaller pieces of
`[0003]
`To address some of these issues, smaller pieces of
`reinforcing materials may be attached to a web or substrate
`reinforcing materials may be attached to a web or substrate
`in selected areas that require reinforcement. The handling
`in selected areas that require reinforcement. The handling
`and attachment of such discrete pieces can, however, be
`and attachment of such discrete pieces can, however, be
`problematic, by potentially reducing throughput, causing
`problematic, by potentially reducing throughput, causing
`waste (where the discrete pieces are not securely attached),
`waste (where the discrete pieces are not securely attached),
`requiring precise registration or location on the web, requir-
`requiring precise registration or location on the web, requir
`ing the use of adhesives or other bonding agents, etc. The
`ing the use of adhesives or other bonding agents, etc. The
`discrete pieces may also present relatively sharp edges that
`discrete pieces may also present relatively sharp edges that
`may be the source of irritation or discomfort. The irritation
`may be the source of irritation or discomfort. The irritation
`or discomfort can be exacerbated because the reinforcing
`or discomfort can be exacerbated because the reinforcing
`pieces are typically located on the surface of the substrate.
`pieces are typically located on the surface of the substrate.
`
`[0004]
`In addition to (or in place of) reinforcing substrates
`In addition to (or in place of) reinforcing substrates
`[0004]
`or webs, it may also be desirable to manufacture articles that
`or webs, it may also be desirable to manufacture articles that
`exhibit elasticity. The manufacture of articles that exhibit
`exhibit elasticity. The manufacture of articles that exhibit
`elasticity, i.e., the ability to at least partially recover their
`elasticity, i.e., the ability to at least partially recover their
`original shape after moderate elongation, may be desired for
`original shape after moderate elongation, may be desired for
`a number of reasons. For example, elasticity may be useful
`a number of reasons. For example, elasticity may be useful
`in connection with fastening systems for items such as
`in connection with fastening systems for items such as
`garments (e.g., diapers, training pants, gowns, bedding,
`garments (e.g., diapers,
`training pants, gowns, bedding,
`etc.). Elasticity in garments can provide what may be
`etc.). Elasticity in garments can provide what may be
`referred to as dynamic fit, i.e., the ability to stretch and
`referred to as dynamic fit, i.e.,
`the ability to stretch and
`recover in response to movement by the wearer.
`recover in response to movement by the wearer.
`[0005] Elasticity may also be useful in connection with
`[0005] Elasticity may also be useful
`in connection with
`other applications. For example, some fasteners may provide
`other applications. For example, some fasteners may provide
`more consistent attachment if the fastener is held in tension
`more consistent attachment if the fastener is held in tension
`that can be supplied by stretching the fastener and relying on
`that can be supplied by stretching the fastener and relying on
`the recovery forces to provide the desired tension. In other
`the recovery forces to provide the desired tension. In other
`instances, elasticity may allow for easy adjustment of the
`instances, elasticity may allow for easy adjustment of the
`size or length of a fastener or other article.
`size or length of a fastener or other article.
`
`[0006] Although elasticity may be beneficial in a variety
`[0006] Although elasticity may be beneficial in a variety
`of different applications, it may raise issues in manufactur-
`of different applications, it may raise issues in manufactur
`ing. Many attempts to provide elasticity rely on separate
`ing. Many attempts to provide elasticity rely on separate
`elastic components that are, e.g., glued or sewn to a backing
`elastic components that are, e.g., glued or sewn to a backing
`or other nonelastic member to provide the desired elasticity.
`or other nonelastic member to provide the desired elasticity.
`The manufacture of such composite articles may be prob-
`The manufacture of such composite articles may be prob
`lematic in that secure attachment of the elastic components
`lematic in that secure attachment of the elastic components
`may be difficult to achieve and/or maintain. Further, the cost
`may be difficult to achieve and/or maintain. Further, the cost
`and difficulty of providing and attaching separate elastic
`and difficulty of providing and attaching separate elastic
`components may be relatively high. The handling and
`components may be relatively high. The handling and
`attachment of separate elastic components can reduce
`attachment of separate elastic components can reduce
`throughput, cause additional waste (where the separate com-
`throughput, cause additional waste (where the separate com
`ponents are not securely attached), etc.
`ponents are not securely attached), etc.
`
`[0007] In other instances, an entire article may be con-
`[0007]
`In other instances, an entire article may be con
`structed to provide the desired elasticity. For example, many
`structed to provide the desired elasticity. For example, many
`elastic fastening systems rely on the use of elastic laminate
`elastic fastening systems rely on the use of elastic laminate
`backings in which the elastic materials are provided in the
`backings in which the elastic materials are provided in the
`form of a film that is coextensive with the backing. Such an
`form of a film that is coextensive with the backing. Such an
`approach may add costs associated with providing a coex-
`approach may add costs associated with providing a coex
`tensive elastic layer or layers. Further, many elastic mate-
`tensive elastic layer or layers. Further, many elastic mate
`rials are not breathable. If the elastic laminate backings are
`rials are not breathable. If the elastic laminate backings are
`to be used in garments, it may be desirable to perforate the
`to be used in garments, it may be desirable to perforate the
`backing to improve its breathability. Such additional pro-
`backing to improve its breathability. Such additional pro
`cessing does, however, add to the cost of producing the
`cessing does, however, add to the cost of producing the
`elastic laminate backing. Another potential disadvantage of
`elastic laminate backing. Another potential disadvantage of
`elastic laminate backings is that it may be difficult to provide
`elastic laminate backings is that it may be difficult to provide
`any adjustment of the elastic recovery forces generated in
`any adjustment of the elastic recovery forces generated in
`different portions of the backing.
`different portions of the backing.
`
`[0008] While a variety of approaches to providing discrete
`[0008] While a variety of approaches to providing discrete
`polymeric structures on substrates are disclosed in, e.g., U.S.
`polymeric structures on substrates are disclosed in, e.g., U.S.
`patent application Ser. No. 10/012,894 filed 5 Nov. 2001 and
`patent application Ser. No. 10/012,894 filed 5 Nov. 2001 and
`titled SYSTEMS AND METHODS FOR COMPOSITE
`titled SYSTEMS AND METHODS FOR COMPOSITE
`WEBS WITH STRUCTURED DISCRETE POLYMERIC
`WEBS WITH STRUCTURED DISCRETE POLYMERIC
`REGIONS; U.S. patent application Ser. No. 10/012,698 filed
`REGIONS; U.S. patent application Ser. No. 10/012,698 filed
`5 Nov. 2001 and titled COMPOSITE WEBS WITH REIN-
`5 Nov. 2001 and titled COMPOSITE WEBS WITH REIN
`FORCING POLYMERIC REGIONS AND ELASTIC
`FORCING POLYMERIC REGIONS AND ELASTIC
`POLYMERIC REGIONS; U.S. patent application Ser. No.
`POLYMERIC REGIONS; U.S. patent application Ser. No.
`10/012,900 filed 5 Nov. 2001 and titled METHODS FOR
`10/012,900 filed 5 Nov. 2001 and titled METHODS FOR
`PRODUCING COMPOSITE WEBS WITH REINFORC-
`PRODUCING COMPOSITE WEBS WITH REINFORC
`ING DISCRETE POLYMERIC REGIONS; and U.S. patent
`ING DISCRETE POLYMERIC REGIONS; and U.S. patent
`application Ser. No. 10/013,304, filed 5 Nov. 2001 and titled
`application Ser. No. 10/013,304, filed 5 Nov. 2001 and titled
`COMPOSITE WEBS WITH DISCRETE ELASTIC POLY-
`COMPOSITE WEBS WITH DISCRETE ELASTIC POLY
`MERIC REGIONS, these approaches may be limited in
`MERIC REGIONS,
`these approaches may be limited in
`certain aspects, such as in roll temperatures, the composition
`certain aspects, such as in roll temperatures, the composition
`of substrates, etc.
`of substrates, etc.
`
`SUMMARY OF THE INVENTION
`SUMMARY OF THE INVENTION
`[0009] The present invention provides composite webs
`The present
`invention provides composite webs
`[0009]
`having one or more polymeric structures located on a
`having one or more polymeric structures located on a
`substrate, methods of manufacturing the composite webs,
`substrate, methods of manufacturing the composite webs,
`and systems for manufacturing the composite webs.
`and systems for manufacturing the composite webs.
`
`[0010] The polymeric structures are formed using thermo-
`[0010]
`The polymeric structures are formed using thermo
`plastic compositions. As used in connection with the present
`plastic compositions. As used in connection with the present
`invention, "thermoplastic" (and variations thereof) means a
`invention, "thermoplastic" (and variations thereof) means a
`polymer or polymeric composition that softens when
`polymer or polymeric composition that softens when
`exposed to heat and returns to its original condition or near
`exposed to heat and returns to its original condition or near
`its original condition when cooled to room temperature. The
`its original condition when cooled to room temperature. The
`thermoplastic compositions used in connection with the
`thermoplastic compositions used in connection with the
`methods of the present invention should be capable of
`methods of the present
`invention should be capable of
`flowing or entering into depressions in a forming tool as
`flowing or entering into depressions in a forming tool as
`described herein.
`described herein.
`[0011] Suitable thermoplastic compositions are those that
`[0011] Suitable thermoplastic compositions are those that
`are melt processable. Such polymers are those that will flow
`are melt processable. Such polymers are those that will flow
`sufficiently to at least partially fill the depressions, yet not
`sufficiently to at least partially fill the depressions, yet not
`significantly degrade during a melt process. A wide variety
`significantly degrade during a melt process. A wide variety
`of thermoplastic compositions have suitable melt and flow
`of thermoplastic compositions have suitable melt and flow
`characteristics for use in the process of the present invention
`characteristics for use in the process of the present invention
`depending on the geometry of the depressions and the
`depending on the geometry of
`the depressions and the
`processing conditions. It may further be preferred that the
`processing conditions. It may further be preferred that the
`melt processable materials and conditions of processing are
`melt processable materials and conditions of processing are
`selected such that any viscoelastic recovery properties of the
`selected such that any viscoelastic recovery properties of the
`thermoplastic compositions do not cause them to signifi-
`thermoplastic compositions do not cause them to signifi
`cantly withdraw from the depressions during wiping of the
`cantly withdraw from the depressions during wiping of the
`molten thermoplastic composition as described herein.
`molten thermoplastic composition as described herein.
`[0012]
`In the methods and systems, the forming tool used
`[0012]
`In the methods and systems, the forming tool used
`to form and transfer the one or more polymeric structures to
`to form and transfer the one or more polymeric structures to
`
`Petitioner - Owens Corning
`
`Ex. 1008, p. 13 of 32
`
`Petitioner - Owens Corning
`Ex. 1008, p. 13 of 32
`
`

`
`US 2004/0178544 Al (cid:9)
`US 2004/0178544 A1
`
`Sep. 16, 2004
`Sep. 16, 2004
`
`2
`
`the substrate is maintained at a roll temperature that is below
`the substrate is maintained at a roll temperature that is below
`the melt processing temperature of the thermoplastic com-
`the melt processing temperature of the thermoplastic com
`position. The melt processing temperature of the thermo-
`position. The melt processing temperature of the thermo
`plastic compositions of the present invention is the lowest
`plastic compositions of the present invention is the lowest
`temperature at which the thermoplastic composition is
`temperature at which the thermoplastic composition is
`capable of flowing or entering into depressions in a forming
`capable of flowing or entering into depressions in a forming
`tool (as described herein) within a period of five seconds or
`tool (as described herein) within a period of five seconds or
`less.
`less.
`
`In some instances, the melt processing temperature
`[0013]
`In some instances, the melt processing temperature
`[0013]
`may be at or slightly above the glass transition temperature
`may be at or slightly above the glass transition temperature
`for an amorphous thermoplastic composition or at or slightly
`for an amorphous thermoplastic composition or at or slightly
`above the melting temperature for a crystalline or semicrys-
`above the melting temperature for a crystalline or semicrys-
`talline thermoplastic composition. If the thermoplastic com-
`talline thermoplastic composition. If the thermoplastic com
`position includes one or more amorphous polymers blended
`position includes one or more amorphous polymers blended
`with either or both of one or more crystalline and one or
`with either or both of one or more crystalline and one or
`more semicrystalline polymers, then the melt processing
`more semicrystalline polymers,
`then the melt processing
`temperature is the higher of the highest glass transition
`temperature is the higher of the highest glass transition
`temperature of the amorphous polymers or the highest
`temperature of
`the amorphous polymers or
`the highest
`melting temperature of the crystalline and semicrystalline
`melting temperature of the crystalline and semicrystalline
`polymers. In addition, it may be preferred that the roll
`polymers.
`In addition,
`it may be preferred that
`the roll
`temperature be at least 20° Celsius or more below the
`temperature be at
`least 20° Celsius or more below the
`temperature of the molten thermoplastic composition depos-
`temperature of the molten thermoplastic composition depos
`ited on the forming tool.
`ited on the forming tool.
`[0014] One potential advantage of maintaining a relatively
`[0014] One potential advantage of maintaining a relatively
`cool forming tool is that the molten thermoplastic compo-
`cool forming tool is that the molten thermoplastic compo
`sition applied to the forming tool (either on its cylindrical
`sition applied to the forming tool (either on its cylindrical
`outer surface or within depressions formed therein) is that
`outer surface or within depressions formed therein) is that
`the molten thermoplastic composition in direct contact with
`the molten thermoplastic composition in direct contact with
`the exterior roll surface falls below the melt processing
`the exterior roll surface falls below the melt processing
`temperature of the thermoplastic composition such that it
`temperature of the thermoplastic composition such that it
`may at least partially freeze or solidify, while at least a
`may at
`least partially freeze or solidify, while at
`least a
`portion of the molten thermoplastic composition located
`portion of the molten thermoplastic composition located
`distal from the exterior roll surface remains molten long
`distal from the exterior roll surface remains molten long
`enough to effect transfer of the thermoplastic composition to
`enough to effect transfer of the thermoplastic composition to
`form the polymeric structures. The result is that the molten
`form the polymeric structures. The result is that the molten
`thermoplastic composition distal from the exterior roll sur-
`thermoplastic composition distal from the exterior roll sur
`face is capable of attaching to a substrate, while the frozen
`face is capable of attaching to a substrate, while the frozen
`or solidified thermoplastic composition in contact with the
`or solidified thermoplastic composition in contact with the
`exterior roll surface releases from that surface cleanly.
`exterior roll surface releases from that surface cleanly.
`[0015] Another potential advantage of maintaining a rela-
`[0015] Another potential advantage of maintaining a rela
`tively cool forming tool is that the composition of the
`tively cool
`forming tool
`is that
`the composition of the
`substrates to which the molten thermoplastic composition is
`substrates to which the molten thermoplastic composition is
`transferred is not limited by the forming tool temperature.
`transferred is not limited by the forming tool temperature.
`For example, the roll temperature may be low enough to
`For example, the roll temperature may be low enough to
`limit any significant damage the substrate during the transfer
`limit any significant damage the substrate during the transfer
`process. As such, the polymeric structures may be formed on
`process. As such, the polymeric structures may be formed on
`porous and non-porous substrates (such as films) that have
`porous and non-porous substrates (such as films) that have
`the same or similar thermoplastic composition as the poly-
`the same or similar thermoplastic composition as the poly
`meric structures. In some instances involving substrates
`meric structures.
`In some instances involving substrates
`formed of thermoplastic compositions themselves, the sub-
`formed of thermoplastic compositions themselves, the sub
`strate thermoplastic composition may preferably have a melt
`strate thermoplastic composition may preferably have a melt
`processing temperature that is at or below the melt process-
`processing temperature that is at or below the melt process
`ing temperature of the thermoplastic composition used in the
`ing temperature of the thermoplastic composition used in the
`polymeric structures formed thereon. The melt processing
`polymeric structures formed thereon. The melt processing
`temperature of the substrate thermoplastic compositions is
`temperature of the substrate thermoplastic compositions is
`subject to the same definition provided above in connection
`subject to the same definition provided above in connection
`with the thermoplastic compositions used to form the poly-
`with the thermoplastic compositions used to form the poly
`meric structures. In addition, it may be preferred that the roll
`meric structures. In addition, it may be preferred that the roll
`temperature be at least 20° Celsius or more below the melt
`temperature be at least 20° Celsius or more below the melt
`processing temperature of the substrate thermoplastic com-
`processing temperature of the substrate thermoplastic com
`position.
`position.
`[0016] Concerns regarding the internal cohesive strength
`[0016] Concerns regarding the internal cohesive strength
`of the substrate and/or the tensile strength of the substrate
`of the substrate and/or the tensile strength of the substrate
`
`may be of more concern if the substrate includes a fibrous
`may be of more concern if the substrate includes a fibrous
`construction (e.g., woven, nonwoven, or knit fibers) that
`construction (e.g., woven, nonwoven, or knit fibers) that
`could be separated from the remainder of the substrate by the
`could be separated from the remainder of the substrate by the
`forces exerted when the substrate is pulled away from the
`forces exerted when the substrate is pulled away from the
`forming tool. These considerations may be limited by the
`forming tool. These considerations may be limited by the
`present invention because of the freezing or solidification of
`present invention because of the freezing or solidification of
`the thermoplastic composition in the depressions. That
`the thermoplastic composition in the depressions. That
`freezing or solidification can limit any forces exerted on the
`freezing or solidification can limit any forces exerted on the
`substrate as the substrate and the polymeric structures are
`substrate as the substrate and the polymeric structures are
`removed from the forming tool.
`removed from the forming tool.
`
`[0017] Another potential advantage of the methods of the
`[0017] Another potential advantage of the methods of the
`present invention is the ability to transfer one or more
`present
`invention is the ability to transfer one or more
`polymeric structures onto a major surface of a substrate
`polymeric structures onto a major surface of a substrate
`while a portion of the thermoplastic composition facing the
`while a portion of the thermoplastic composition facing the
`substrate is molten. If the substrate is porous, fibrous, etc.,
`substrate is molten. If the substrate is porous, fibrous, etc.,
`pressure may enhance attachment of the one or more poly-
`pressure may enhance attachment of the one or more poly
`meric structures to the substrate by forcing a portion of the
`meric structures to the substrate by forcing a portion of the
`thermoplastic composition to infiltrate the substrate and/or
`thermoplastic composition to infiltrate the substrate and/or
`encapsulate fibers of the substrate. If the substrate is not
`encapsulate fibers of the substrate. If the substrate is not
`porous, but is made with a thermoplastic composition that
`porous, but is made with a thermoplastic composition that
`has a melt processing temperature sufficiently low relative to
`has a melt processing temperature sufficiently low relative to
`the temperature of the molten thermoplastic composition in
`the temperature of the molten thermoplastic composition in
`the depressions, then attachment of the polymeric structures
`the depressions, then attachment of the polymeric structures
`may be achieved by intermixing of the thermoplastic com-
`may be achieved by intermixing of the thermoplastic com
`positions in the polymeric structures and the substrate.
`positions in the polymeric structures and the substrate.
`
`[0018] Another potential advantage of the present inven-
`[0018] Another potential advantage of the present inven
`tion is the opportunity to provide polymer structures that
`tion is the opportunity to provide polymer structures that
`include surface features formed on their upper surfaces (i.e.,
`include surface features formed on their upper surfaces (i.e.,
`the surfaces facing away from the substrate). The surface
`the surfaces facing away from the substrate). The surface
`features may be, e.g., stems, hooks, pyramids, channels,
`features may be, e.g., stems, hooks, pyramids, channels,
`indicia (alphanumeric or otherwise), etc. and may provide
`indicia (alphanumeric or otherwise), etc. and may provide
`additional functionality such as, e.g., mechanical fastening,
`additional functionality such as, e.g., mechanical fastening,
`etc. These surface features may be provided in an integral
`etc. These surface features may be provided in an integral
`process step at the same time as formation and transfer of the
`process step at the same time as formation and transfer of the
`polymer structures themselves (as opposed to a separate,
`polymer structures themselves (as opposed to a separate,
`subsequent process step). Alternatively, though, the surface
`subsequent process step). Alternatively, though, the surface
`features could be provided after formation of the polymer
`features could be provided after formation of the polymer
`structures.
`structures.
`
`[0019] Another potential advantage is the ability to control
`[0019] Another potential advantage is the ability to control
`